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To tackle we need to fix what we can.
Starting with the restricted airflow.
When you remove the top cover plate
There is a second metal plate.
This already gives a larger space to receive fresh, less restricted airflow.
And gives an opertunity for hot air to escape.
That's a quick and easy fix.
Next step obviously is not to place the cover plate at the bottom.
Remove the filter and cover plates on the side.
Last more or less "easy fix" is to replace the fans.
First thing to know is that you need 4 pin pwm fan, 12v.
Second thing is that Sorotec used their own pin layout... You can not use the standard 4 pin connector but need to change 2 wires.
Tach and 12v different place ??
If you want to change the fans, because even after opening everything up to make it more silent/ less noisy...
You no longer need hearing protection, but it absolutely isn't silent.
I've done extensive research on fans.
In a nutshell the silent ones usually don't generate enough Static pressure or enough M3 airflow.
My best advice is "silent wings 3".
Even at high speed they are quiet.
Not silent, but so much better.
If you want to make it really silent..
You need to cut some iron and reverse the airflow.
I opened the second top sheet.
Took out the 2 fans at the bottom.
Closed the air inlets at the side.
And made 2 ducts.
The one at the bottom blows fresh air inside, the duct at the top sucking it out.
Push-pull configuration.
4 x silent wings 3, 120mm, high speed.
This is what it looks like:
In the past I have lost a few inverters.
Amazing quality, except crap Thermal management. Fans didn't start under 500 watt draw.. causing it to slowly heat up and fry internal at the hotspots.
As a result I don't completely thrust Thermal management from China.
Loosing $2400 might have something to do with that
The top fans are Controlled by the Revo.
The bottom fans are always on top speed.
I used to have some china controller in between...
-China... Didn't last that long ?
Doesn't matter much.
At high speed (2500rpm) under 35db, and 2.5 watt...
Normal speed (1500rpm) under 17 db and 1.5 watt.
Lifetime about 30 years at full speed.
I don't know if it will make this, but liquid bearing...
I have a noctua fan, spinning since 2008 and as silent as the day I bought it.
Sadly crappy Static pressure, I've tried them... Good for unrestricted airflow.
That was rated 100.000h MTBF, silent wings are 300.000.....
At full speed a slight humming sound, nothing bad. Split Aircon indoor unit makes more noise with air circulation.
(New Daikin 9000BTU unit)
Obviously, you will void warranty when you start cutting metal.
Your environment needs to be suitable.
That is a closed space where no animals can enter the inverter. No children can sick their fingers in a fan, or spill drinks inside the unit...
Thailand is HOT from time to time, and the room with the inverters is regularly above 35c, sometimes above 45c if I forget to turn on the air-conditioning.
I need this strong airflow, high pressure and for piece of mind a double setup for the fans.
Replace the 80mm with 2 silent wings,
Open the top and make a simple duct for 2 120mm to blow into the Revo probably already will solve your problem.
There are splitters for fans, so easy enough to connect 4.
Energy draw will be lower then original, also not a problem.
And how simple a duct can be?